Interventions in flat rolling mills begin with targeted targeted on-site assessments and fact-finding. With SMS group's mill health check program, plant operators benefit from a thorough, neutral analysis of their plants' mechanical and hydraulic systems, processes, automation, and software. Visual inspection, 3D laser tracker measurements, material analysis and comprehensive documentation create a clear, data‑driven basis for decision making. Results are reviewed with the customer and translated into repair concepts and execution drawings by SMS group’s engineering teams.
Recommendations for short, mid, and long-term actions are made, where SMS leverages the experience gained from its extensive installed base at various locations to provide detailed reports to customers. The comprehensive health check conducted at Steel Dynamics in Butler, Indiana, USA, is an initiative SMS hopes to replicate across its customer base to build proactive and strong partnerships.
It was a great experience to have SMS group at our site and we gathered at least seven relevant topics with good ideas that we are planning to follow up on going forward. We would be glad to host another mill health check for SMS in the future.
Mill upgrades and modernizations
Where appropriate, upgrades or modernizations are integrated so that each intervention becomes an opportunity to improve yield, quality and energy efficiency rather than merely restoring the original condition. On‑site machining and coordinated execution under a single accountable partner, such as SMS group, avoid lengthy disassembly and transport, shorten downtime and reduce total repair cost while restoring geometry and extending component life.
A successful modernization of the rotary mandrel at Acciaierie d’Italia's (ADI) cold rolling mill in Genova, Italy after 15 years of relentless operation is an example of practical on-site intervention. SMS tackled significant wear and replaced critical components, including spherical plain bearings, hollow shafts, and spur gears, all on-site. The 24-hour operation during the repair work enabled a swift resumption of production, minimizing downtime and ensuring maximum efficiency. Proactive inspections since 2019 allowed SMS experts to identify maintenance needs in advance. ADI was fully prepared for this seamless upgrade, saving valuable time and costs.
The partnership with SMS group has proven invaluable for the maintenance and optimization of our plant. Thanks to precise planning, innovative technologies, and seamless coordination, we efficiently implemented the repair of our rotary mandrel, saving valuable time and costs while improving the plant's reliability and performance.
Mill Stand Assessment to detect wear and damage in mill stand components
A common example in flat rolling mills is wear and damage in mill stand components, which often first become apparent at the product level through reduced surface quality, edge defects, inconsistent strip thickness and forming anomalies. These symptoms point to root causes in the alignment of the mill stand, the mill stand window itself or the support systems.
After on‑site diagnosis and evaluation by the service team, repair concepts can range from local machining of wear plates surface and reconditioning of bearing seats to full replacement of wear plates, housings or structural elements. Precision machining on site restores critical geometries such as bearing bore concentricity and the planarity of mating surfaces for the wear plates, while FEM analyses validate that the repaired or upgraded configuration will withstand expected loads without introducing new stress concentrations.
This combined approach - rigorous diagnosis, validated engineering, appropriate material selection and precision on‑site execution - restores mill stand integrity, improves product quality, extends service intervals and delivers measurable reductions in lifecycle cost and unplanned outages. Measurement and integrated analysis of mill stand alignment and chock geometry enable SMS group experts to consolidate data and improve diagnostic accuracy.
Value of an Oil System Assessment
Oil losses in brownfield hot strip mills and heavy plate mills can reach staggering levels — up to 500,000 liters per year. Water ingress into oil lubrication systems, often caused by faulty seals or cooling units, can raise water content beyond permissible limits and force production stoppages. Under time pressure, maintenance teams frequently apply ad‑hoc remedies such as instinctive seal replacements instead of addressing root causes. These reactive measures fail to eliminate the underlying problems and increase operational expenditure (OPEX) while reducing plant efficiency.
This is where the Oil System Assessment adds value. SMS group experts perform a thorough on‑site evaluation to identify hidden inefficiencies and recommend targeted solutions. The assessment starts with a detailed analysis of existing system data combined with precise measurements to reveal deficiencies that might otherwise remain undetected. The team then reviews the facility’s design and operating parameters to identify areas requiring modification or redesign. This holistic approach ensures oil flow rates, pressures, temperatures, and viscosities are optimized for actual operational needs rather than based on outdated assumptions or conservative safety margins.
By proactively addressing oil losses and water ingress, businesses can realize substantial cost savings and improve compliance with environmental regulations. The tailored roadmap from SMS group experts supports seamless implementation of recommended measures without disrupting production. In short, the Oil System Assessment is a strategic investment in quality, efficiency, and productivity — enabling rolling mills to reduce OPEX and secure long‑term reliability.
Integrated lifecycle support
SMS group bundles engineering, on‑site management and execution, coordinating qualified local sub‑suppliers as needed to ensure consistent quality and schedule adherence. Deployed worldwide with 24/7 emergency readiness and deep metallurgical, mechanical and automation expertise, SMS group’s field services support installations for flat, long and forged products as well as metallurgical plants and enable seamless integration between mechanics, electrics and automation.
Complementary offerings such as long‑term service contracts, spare‑parts supply, plant audits, training and consulting provide predictable maintenance, continuous performance monitoring and strengthened in‑house capabilities, allowing customers to maximize operational excellence and the lifetime value of their assets rather than merely responding to breakdowns.